How 3D printing adds up for

Business Aviation

PRESENTED BY:

James Kulp, CAM

May 3, 2017| 10:45 – 12:00

2

Beam me up, Scotty

There’s no sign of intelligent life

Tea…

Earl Grey, Hot

3D printing

or

3

What is 3D printing

• 3 Dimensional printing is a process of making physical parts from a digital file

• 3D printing is some times called Additive Manufacturing, AM, which describes the

printing process

• Additive process is the joining of materials to objects in successive layers to form the

shape of parts

• Additive manufacturing is a synonym with metal 3D printing

• Enables rapid prototyping to make parts or molds for parts

• With new designs, allow freedom to innovate complex designs and geometries

4

Hype versus reality

Technology

breakthrough

Increasing

expectations

Technology shake out

2nd & 3rd gen

breakthroughs

MainstreamInnovation Trigger Peak of

Inflated

Expectations

Trough of

Disillusionment

Slope of

Enlightenment

Plateau of

Productivity

Gartner Hype Cycle: Emerging Technologies

4D Printing

Commercial

UAVs

Connected

homes

Brain computer interface

Autonomous Vehicles

Source: Gartner

Virtual reality

Augmented reality

Exp

ecta

tion

s

Time

5 – 10 Years

More than 10 Years

5Source: Gartner

6

Pace of change

Evolutionary versus revolutionary

2,000,000 bc

Stone tools

Bronze tools

3,300 bc

Iron tools

1,200 bc 1780 1848 1895 1940 1969 2017

Source M. Hilbert, University of California

Water

wheels

Steam engines

Electrical

engineering

Automobile

Aircraft

Cyber

Digital & Physical

convergence

4th3rd

7

Industrial revolution

The dawn of the 4th industrial revolution

Source: World Economic Forum

2nd1st

Mechanization: Railroads & steam

power

1784

Mass Production: Division of labor, mass

production & electrical power

1870

Computer & automation

1969

Cyber-physical systems

Now

Deg

ree

of

com

ple

xity

Industry 4.0

Industry 3.0

Industry 2.0

Industry 1.0

Combines

communication,

IT, data &

physical

elements

integrating a

number of

technologies

8

3D printing

Architecture

Automotive

Consumer

HealthcareEntertainment

Apparel

Education

Industrial

Food

9

3D printing

Additive versus subtractive

Subtractive

Additive

Machined

Layer deposition

Pro

ce

ss

Volume Cost/Unit Time to Market Cost of Complexity

Attrib

ute

s

Material Scrap / Waste

10

3D printing for product development

Prototyping

Cost reduction

Innovation

Efficiency

All new productNew sub-systemNew componentDesign verification

Category "Ink" Power Source

Thermoplastics

Ceramic slurries

Metal paste

SLS Selective Laser Sintering Polymer

DMLS Direct Metal Laser Sintering

DMLM

Electron Beam

Vat PhotopolymerizationSLA Sterolithography

Photopolymer

CeramicsUltraviolet Laser

MJ Metal Jetting Plastic

NPJ Nano Particle Jetting Metal

DOD Drop on Demand Wax

Polymer powder

Ceramic powerer

Metal powder

Gypsum

Sand

Plastic film

Metalic sheet

Ceramic tape

Composite

Paper

LENS Laser Engineering Net Shape

EBAM Electron Beam Additive Manf.Laser BeamMolten metal powderDirected Engergy Ddeposition

Thermal EnergyMaterial Jetting

Thermal EnergyIndirect Injet PrintingBinder Jetting BJ

Sheet Lamination LOM Laminated Object Manufacturing Laser Beam

Technology

FDM Fused Deposition ModelingMaterial Extrusion

High-powered laser BeamPowder Bed Fusion

Atomized metal powered

Stainless steel

Cobalt Chromium

Titatinium

Ceramic powder

Selective Laser Sintering

Direct Metal laser Melting

Electron Beam MeltingEBM

SLM

Thermal Energy

3D printing technology types

Source: 3Dhubs.com, Explainingthefuture.com

12

Additive in aerospace

Source: 3D Printing industry.com, Investors Business Daily

manufacturing cost

DECREASES

design complexity

INCREASES

WITH

ADDITIVE

MANUFACTURING

14

GE Additive

GE Additive

Power Aviation Transportation Oil & Gas Healthcare Medical Automotive

16

GE Aviation Additive examples

All new productNew sub-systemNew componentDesign verification

Capabilities of full production35,000 – 40,000 per year

LEAP fuel nozzle

PARTS

DURABLEMORE

WEIGHT REDUCTION

LEAP is a trademark of CFM International, a 50/50 JV between GE and Safran Aircraft Engines

20 1

525

17

Solution for traditional

engine shut-down fuel coking

19 additive fuel nozzles per engine

Advanced Turboprop engine (ATP)

PARTS

WEIGHT REDUCTION

Combustor test schedule reduced from 12 months to 6 months

LOWER MISSION

FUEL BURN

5

20

855 1218

19

GE Additive examplesHeat exchanger journey

All new productAdvanced traditionalTraditional

GE’s additive global network

20

21

Competency and skills associated with 3D printing technologies

Function Importance Degree of skill change

required

New skills Evolution of existing skills

Engineering 3DP operations: ability to operate & perform task to run new printers

Maintenance repair & training: leverage current skill set to support 3DP

Education 3DP teaching: understand fundamentals & trends (tech & business)

3DP curriculum: create courses – concept to application

New product design

3DP design: convert 3D from 2D. 3DP fundamentals: process & capability

Design velocity: software support for customization

Sales & marketing

3DP market education: promote 3D products Activity velocity: rapid rate support new product launches

Human Resources

3DP high-level understanding: communicate capabilities

Employee retention: create strategies to maintain 3DP qualified employees

Procurement Sourcing strategy: understand market for materials, software, hardware

Supplier qualification: new criteria for 3DP

Aircraft Maintenance

Maintenance & support strategy: Understand3DP repairability, logistics, material, technology

Integration of 3DP into maintenance plan. Supplier & employee development

Workplace implication

Source: Adapted from Technology and Innovation for the Future of Production: Accelerating Value Creation: World Economic Forum

High Low

DO

M

22

Ready for the next revolution?

Source: Future of Jobs Report: World Economic Forum

35%Skills change

Thank You